Senior Process Engineer

Movement Search and Delivery is working with a leading manufacturing company in Dunkirk, NY to identify and evaluate a Sr. Process Engineer.

About the Role:

This position serves as a senior technical role responsible for open-die and GFM forging processes. The role is accountable for developing, optimizing, and sustaining forging and associated thermal processes to meet customer requirements, ensure stable and capable production, and drive cost competitiveness. The individual will work cross-functionally with operations, maintenance, engineering, and commercial teams, while directly interfacing with customers to support material qualification, process development, and technical issue resolution. This position is expected to grow into the primary technical point of contact for forging processes at the facility.

What You Will Do:

-Establish and own forging process capability for open-die and GFM operations, including control of:

• temperature
• strain and reduction
• thermomechanical processing windows

-Develop, validate, and optimize:

• forging routes and reductions
• furnace parameters and heat treatment cycles
• process windows to achieve required mechanical properties and quality

-Lead customer qualification and development programs, including:

• new material introduction
• process qualification and validation
• alignment of customer requirements with plant capabilities

-Drive cost reduction, yield improvement, and throughput optimization through metallurgical and process improvements

-Develop and maintain:

• forging programs and tables for 4K press and GFM
• process standards for both internal products and outside conversion customers
• Disposition and close variances or upgrade to IRR if needed

-Serve as the technical lead for outside conversion business, including:

• development of forging approaches and routings
• support for quoting and cost structure definition
• identification of new opportunities to grow Dunkirk conversion volume

-Define and implement process monitoring and control systems, including:

• SPC and capability tracking
• acquisition and analysis of process data
• correlation of process parameters to product performance

-Partner with maintenance and engineering to:

• commission and implement new equipment
• define and maintain operating envelopes
• improve process reliability through technical understanding

-Lead technical resolution of:

• internal process issues
• customer quality concerns
• deviations and non-conformances

-Provide technical leadership and mentorship to engineering and operations personnel

Key Responsibilities

• Define, control, and continuously improve key forging and thermal process parameters- review and update SPC data
• Monitor and drive product performance (mechanical properties, surface condition, dimensional characteristics, yield)
• Review and interpret customer specifications and ensure technical compliance
• Maintain process documentation control systems and associated databases
• Support management review with data-driven analysis and recommendations
• Interface with customers, sales, and leadership to resolve any differential between customer requirements and company capabilities.
• Technical supervision of company processes and employees

What You Need to Succeed:

• Bachelor’s or Master’s degree in Metallurgical Engineering or Materials Science
• Minimum 8–12 years of experience in forging and thermomechanical processing of high-performance alloys

About Movement Search and Delivery:

MOVEMENT is a national executive search firm that connects companies with exceptional talent across engineering, manufacturing, finance, supply chain, information technology, sales, legal, and human resources.

How to Apply:

Apply through this posting and a member of the Movement Search and Delivery team will review your application. For more information on open jobs, visit www.movementsearch.com.

This position requires use of information or access to production processes subject to national security controls under U.S. export control laws and regulations (including, but not limited to the International Traffic in Arms Regulations (ITAR) and the Export Administration Regulations (EAR)). To comply with those regulations, this position may require applicants to be U.S. Persons (i.e., U.S. citizens, U.S. lawful permanent residents, protected individuals as defined by 8 U.S.C. 1324b(a)(3)), or eligible to obtain the required export authorizations from the U.S. Department of State or the U.S. Department of Commerce.